1. PAINPOINT DRIVEN OPENING

Is your foundry or steel plant’s coke handling process a persistent bottleneck? The screening of metallurgical coke is critical, yet often plagued by inefficiencies that directly impact your bottom line. Common operational challenges include:

Blinding & Carryover: Fine particles and moisture cause screen mesh blinding, reducing effective screening area. Simultaneously, oversized material carries over into the product stream, contaminating blast furnace feed and compromising furnace efficiency.
Excessive Downtime & Maintenance: Traditional screens with complex drive mechanisms and numerous bearings require frequent lubrication and are prone to mechanical failure, leading to unplanned shutdowns and high spare parts inventories.
Low Screening Efficiency & Capacity: Inadequate vibration dynamics result in poor material stratification and rapid travel speed, causing fines to bypass the screening process. This forces recirculation of material, wasting energy and limiting overall plant throughput.
Structural Fatigue & Noise: Highstress, unbalanced forces from conventional exciters transmit damaging vibrations to the support structure and generate excessive noise levels, raising safety concerns and increasing longterm facility maintenance costs.

Are you seeking a screening solution that delivers consistent product grade, maximizes uptime, and provides a measurable return on investment through reduced operational expense?

2. PRODUCT OVERVIEW

The Professional Coke Vibration Screen is a highcapacity, linear motion vibrating screen engineered specifically for the rigorous dry screening of metallurgical coke in sizing (e.g., 2580mm) and scalping applications. Its design focuses on reliability, accuracy, and low total cost of ownership in heavyduty industrial environments.

Operational Workflow:
1. Feed & Distribution: Coke feedstock is evenly distributed across the full width of the screen via an integrated feed box or chute.
2. Stratification & Separation: A controlled linear vibratory motion stratifies the material bed, allowing fines to contact the screen media while conveying larger particles along the deck length.
3. Size Segregation: Properly sized coke passes through the screen apertures as product, while oversize material is discharged at the end of the deck.

Application Scope: Primary sizing of blast furnace coke (BF Coke), coke breeze separation, scalping of coke oven feedstock. Ideal for postcrusher screening in coke processing plants.
Limitations: Not designed for wet screening applications or for materials with extreme adhesive properties without specific deck modifications.

3. CORE FEATURES

Dual CounterRotating Exciter System | Technical Basis: Synchronized eccentric shafts generating a true linear force | Operational Benefit: Produces a consistent straightline motion for optimal material conveyance and stratification with minimal stress on the frame | ROI Impact: Higher screening efficiency (typically +1520%) increases yield of onspec product and reduces reprocessing costs.

Modular Deck Design | Technical Basis: Independently tensioned screen panels mounted on a robust subframe | Operational Benefit: Allows for rapid panel replacement (<4 hours vs. fullday downtime) and easy adaptation to different aperture sizes or wear materials (rubber, polyurethane, steel) | ROI Impact: Cuts maintenance downtime by up to 60% and simplifies inventory management.

HeavyDuty Coil Spring Isolation | Technical Basis: System of highcycle fatigueresistant steel coil springs supporting the vibrating frame | Operational Benefit: Isolates up to 80% of dynamic forces from the support structure, protecting building integrity and reducing noise pollution | ROI Impact: Eliminates costly structural reinforcements and minimizes environmental compliance issues.

Centralized Grease Lubrication | Technical Basis: Automated lube lines feeding highcapacity bearings within sealed exciter assemblies | Operational Benefit: Ensures optimal bearing life with minimal manual intervention; grease intervals can be extended to 500+ hours | ROI Impact: Reduces lubrication labor by ~75% and prevents premature bearing failure, a leading cause of catastrophic screen stoppage.

DustEnclosed Design | Technical Basis: Integral dust sealing flanges at feed/discharge points and between deck sections | Operational Benefit: Significantly contains airborne coke dust at transfer points, improving site housekeeping and operator safety | ROI Impact: Lowers exposure risks and reduces load on downstream dust collection systems for auxiliary energy savings.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Conventional Screens) | Professional Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Screening Efficiency (Dry Coke) | 8590% under optimal conditions | Consistent 9497% efficiency across duty cycle| +7% average increase |
| Bearing Service Life (L10) | ~12,000 15,000 hours with manual lube| >20,000 hours with centralized lubrication| +33% longer lifespan |
| Annual Maintenance Downtime| 120 180 hours for inspections & repairs| 50% reduction |
| Force Transmission to Base| High dynamic load factor (>4.0 G's)| Low dynamic load factor (<2.5 G's)| ~40% less structural stress |
| Noise Level at 1 Meter Distance| Typically 9095 dB(A)| Typically <85 dB(A)| ~10 dB(A) reduction |

_Estimates based on field data from continuous operation._

5. TECHNICAL SPECIFICATIONS

Model Range & Capacity: Available in widths from 1.5m to 3.5m; lengths from 5m to 10m. Capacities from 300 MTPH to over 1500 MTPH depending on aperture size and feed gradation.
Power Requirements: Drive motor ratings from 15 kW to 55 kW (400/690V AC), variable frequency drive optional for startup control.
Material Specifications: Main frame constructed from S355JR structural steel; side plates are abrasionresistant steel (AR400). Screen decks support polyurethane or rubberclad wire mesh panels.
Physical Dimensions (Example Model CPVS2448): Width: 2.4m; Length: 7.3m; Height (from base): ~2.1m; Approximate Weight: ~12 tonnes.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; suitable for outdoor installation with standard IP65 protection on electrical components.

6. APPLICATION SCENARIOS

Integrated Steel Plant – Blast Furnace Feedstock Sizing

Challenge: A major steel producer experienced inconsistent blast furnace performance due to oversized (+80mm) coke carryover from aging screens causing irregular burden permeability.
Solution: Installation of two parallel Professional Coke Vibration Screens configured with top decks featuring tapered slot polyurethane panels for precise separation at cut points of >25mm / >40mm / >80mm.
Results: Oversize contamination reduced by over 98%. Screening efficiency stabilized at 96%, contributing to a measured 3% reduction in blast furnace coke rate within six months due to improved burden distribution.

Merchant Coke Producer – Scalping PostCrushing

Challenge: Frequent blinding of screen cloth by sticky fines led to daily manual cleaning stops (~2 hours each), limiting plant throughput despite crusher capacity being available.
Solution: Deployment of a singledeck Professional Coke Vibration Screen equipped with hightension stainlesssteel wire mesh featuring antiblinding ball trays underneath each panel section.
Results: Blinding incidents eliminated entirely between scheduled monthly shutdowns.The plant achieved its designed capacity target consistently,saving an estimated 500 production hours annually previously lost to cleaning downtime.

7.COMMERCIAL CONSIDERATIONS

Equipment pricing is structured into three tiers based on size,duty,and customization:
1.Standard Duty Series: For capacities upto 600 MTPH.Best suited for final product sizing.Fixed price basis includes basic dust covers,ladder,and walkways
2.HeavyDuty Series: For capacities upto 1200 MTPH.Includes reinforced frames,larger diameter shafts,and premiumgrade bearings as standard.Optional features include explosionproof motors,VFD soft starters,and automated tensioning systems
3.Custom Engineered Solutions: For ultrahigh capacity (>1200 MTPH) or unique layouts.Includes full CFD analysis feedbox design custom isolation solutions

Service packages are offered separately ranging from basic commissioning supervision comprehensive multiyear maintenance agreements covering parts labor predictive inspections

Financing options including equipment leasing capital expenditure loans available through certified partners typically structured over 36 60month terms

FAQ

Q1.Is this equipment compatible with our existing conveyor layout?
A.The Professional Coke Vibration Screen can be engineered interface most standard conveyor heights discharge arrangements Feed boxes discharge hoods customized match your specific transfer points ensuring smooth integration minimal civil work required

Q2.What impact will installation have ongoing production?
A.Field data shows typical installation commissioning period ranges 10 14 days depending foundation requirements Our project teams specialize fasttrack installations minimize disruption often utilizing planned maintenance windows

Q3.How does this solution address abrasive wear compared traditional screens?
A.Key wear components like side liners discharge lips manufactured AR400 AR500 steel replaceable modular sections This design localizes wear simplifies replacement reduces cost compared replacing entire structural panels common older designs

Q4.Are spare parts readily available?
A.We maintain global network certified parts depots Critical rotating components like shaft assemblies bearing cartridges standardized across model range ensuring availability Stock items typically shipped within 48 hours nonstock items within 10 working days

Q5.Can you provide documented evidence performance claims?
A.Upon request we provide detailed test reports certified thirdparty laboratories along anonymized case studies existing clients These documents include before/after data screening efficiency throughput maintenance logs support our stated performance metrics

Q6.What typical warranty coverage offered?
A.Base warranty covers defects materials workmanship period months operation whichever comes first Extended warranties available critical components including exciter assemblies mainframe structure under separate service agreement terms